RC's M38

[rccolacc]

Well I'm back in Starkville, and Mark Guyton has given me space in his shop, so it's time to start working on the M38. I feel like I need to start a build thread mostly to get motivated to start.
The M38 is currently in Raymond at my parent's farm. Here's what it looks like:





Craig Ellis Sasser sold me the Jeep a few years ago.
Specs are: Dana 18 transfer case, Wagoneer Dana 44 offset axles, leaf springs (wagoneer and YJ), and a mid-80" wheelbase. Here's a link to what he did:
muddawg95yj.proboards.com/index.cgi?board=projects&action=display&thread=1310

My plans are:
-coil suspension (4 link in rear, radius arm in front) with TJ springs
-5.2L (318ci) V8 and auto trans from a wrecked '95 ZJ I have
-231 transfer case
-Dana 44s from a wagoneer (driver drop front, centered rear)
-Roll cage
-35" tires

I want to keep the stock frame (not doing a buggy), and I'd like to make it streetable (if it's possible) so I can drive it around here on nice days. I'm not sure what I want the wheelbase to be, but I'm thinking 90"+.

Here's some links to some builds on Pirate I've been following:
www.pirate4x4.com/forum/showthread.php?t=703554&highlight=flattie
pirate4x4.com/forum/showthread.php?t=727812
pirate4x4.com/forum/showthread.php?t=424008

This is one I really like:
www.jeepingoffroad.com/Willys.htm

[rccolacc]

Step 1: Space needs to be made in Mark's shop. He's wanting to sell his Ford Model A. Here's some pictures. Know anyone that wants a Model A?









More pictures here:
smg.photobucket.com/albums/v409/rccolacc/Model%20A/

[Rusty H]

I want the Model A . How much?
662-213-1430

[rccolacc]

Answered your PM. Talk to Mark Guyton about price.

[broncocraigellis]

My offer still stands...you'll wear down one day.

I would like to pick up the axles when you swap them around.

[rccolacc]

Yeah I plan on calling you when I pull them. Would you like the Dana 18 as well? Know anyone with some Wagoneer Dana 44s (driver drop front)?
-RC

[broncocraigellis]

Ha. I scrapped the one you need a couple of years ago. I don't know of any local to you, but there used to be several in Corinth if he hasn't crushed them.

[troopermc]

Awesome!! I have to keep an eye on this, I have a 1951 M38 collecting dust in my shop, along with a set of passeneger drop D44s.

[rccolacc]

Update:
Got a dana 44 front and Model 20 rear from an '84 Grand Wagoneer. I got them from a junkyard in Cleveland for $300/pair. Would've rathered have the Dana 44 rear, but the model 20 on the FSJs is just as strong (from what I've read anyway) and I couldn't find a dana 44 rear. They're in the 87-91s apparently and I couldn't find any.

Mark's still working on selling the Model A, which should happen soon. Lots of calls from the Tradewinds ad...

Since I've got access to all kinds of cool tools at work, I decided to draw up the M38 in the 3D software we have here at work. So far I've got the frame, rough axles, and TJ 3" lift springs.



I'm not sure how detailed I'm going to get it. It would be nice to put the whole M38 in there, but it would just take loads of time to draw in CAD. I think I want to do the suspension links and figure out the rear 4 link and then call it good for the 3D modeling. I may change my mind later though.
-RC

[troopermc]

RC- some argue that the FSJ Model 20 (Actually called M23) is stronger than the Dana 44 rear. It has a larger ring gear than the 44.

ok...enough talk..lets see the progress pics!!!!!!!!

[rccolacc]

Did some more work this weekend. Mark and a friend helped me remove the body and I started work on the frame. I hope to take the old axles out soon. I removed the old motor mounts and did some grinding on the frame. I'm going to plate it where the new motor mounts are going to go, as well as where the front suspension is going to attach.

[rccolacc]

Updates:

Cut the old suspension off:




Craig needs to get this at some point:


Cut the brackets off the front axle:


Gears look good and oil looks clean:

[rccolacc]

Cutting and fitting more frame plating:




Cut some large tube for jackstands:


Set the frame height at ride height:




Fit the stand top to the frame so it won't slip off:


Old dana 30 from an XJ for mock-up:


I'm going to use the XJ dana 30 for long-arm mock-up while I regear the Dana 44 and put suspension brackets on it. The 30's a lot easier to move around the shop than the 44.
Regear will be soon-- I'll let everyone know. I need one more part for the front 44 and I'll be good to go for the gear setup party.
-RC

[rccolacc]

More updates:
Invited some guys from work to help tear apart the Dana 44:




Had to get creative to get the bearing retainers out. Since autozone was about to close I just made my own tool:


The spindles were really hard coming off, but they finally gave up. Got the shafts out.




Jeff (coworker at Aurora) got some MIG time in and helped me put the plates on the frame:

[rccolacc]

Finished welding:




Dana 44 regear:




This pretty much sums up the night:

My boss Dow (on the right) came for moral support and to keep us honest. I'm glad he came-- he was a big help, especially when it came to adding the shims and getting it right. The battery died on my set of calipers, and without his manual set, we would've been stuck. Jeff got the locker installed and put the ring gear on the carrier. We got the new races in and set the ring gear backlash. We still need to paint the gears and make sure the pinion depth is good. I'll probably get to that Monday.

New races and cleaned up:


More to come after the gear set-up is done.
-RC